Carpet embossing in register with print

ABSTRACT

Pile fabrics prepared from nylon carpet fibers having a textured or embossed surface and a process of developing the textured effect which comprises selectively contacting the surface of said carpet with a chemical fiber shrinking agent therefore, allowing the shrinking action to occur and, thereafter, effectively removing the shrinking agent from the surface, said shrinking serving to reduce the height of the pile in the treated areas and creating said textured surface.

United States Patent [19] Palmer et al.

[4 1 Nov. 19, 1974 CARPET EMBOSSING IN REGISTER WITH PRINT Inventors:Leon B. Palmer, Little Falls; Robert P. Conger, Park Ridge, both of NJ.

Assignee: Congoleum Industries, Inc., Kearny,

Filed: Aug. 6, 1973 Appl. No.: 386,047

U.S. Cl 117/11, 26/69 B, 28/76 P, 156/277, 161/63 Int. Cl. B44d l/02,B44d 5/02, D03d 27/00 Field of Search 161/63; 156/277; ll7/8.5, 117/9,11; 26/69 B; 28/76 P References Cited UNITED STATES PATENTS 3/1896Wissel et al. 26/69 B 4/1917 Zeidler 26/69 B UNTREATED FIBEZS7 BACKlNG1,655,414 1/1928 Flory 26/69 B 1,834,339 12/1931 Dreyfus et al. 26/69 B2,020,698 11/1935 Platt 161/63 2,875,504 3/1959 White 161/63 2,901,3738/1959 Weiss 117/11 3,567,548 3/1971 Miller 156/277 PrimaryExaminer-William J. Van Balen Attorney, Agent, or FirmRichard T.Laughlin, Esq.

[5 7] ABSTRACT Pile fabrics prepared from nylon carpet fibers having atextured or embossed surface and a process of developing the texturedeffect which comprises selectively contacting the surface of said carpetwith a chemical fiber shrinking agent therefore, allowing the shrinkingaction to occur and, thereafter, effectively removing the shrinkingagent from the surface, said shrinking serving to reduce the height ofthe pile in the treated areas and creating said textured surface.

30 Claims, 2 Drawing Figures FIBERS TREATED WITH EMBOSSING AGENTKUNTREATED FIBERS PATENTE HOV I 9 I974 EMBOSSED AREA UNTREATED AREAUNTREATED FIBERS TREATED WITH EMBOSSING AGENT FIBERAS7 UNTREATEDIFIBERSL BACKING CARPET EMBOSSING IN REGISTER WITH PRINT BACKGROUND OF THEINVENTION In the production of nylon piles fabrics, it is often sirableto emboss the surface thereof in order to provide added decorativeappeal. In some instances, the embossed areas are printed with dyes tofurther embellish the surface design.

Embossing of pile fabrics is conventionally accomplished with a heatingembossing roll or plate which has been engraved or otherwise treated tocreate the design desired in raised relief on the surface. A methodwhich eliminates the use of embossing rolls has been disclosed in U.S.Pat. Nos. 2,790,255 and 2,875,504. In accordance with these patents, thepile fabric is formed from a combination of shrinkable andnon-shrinkable yarns. Upon subjecting the fabric to the influence ofheat, the pile formed from the shrinkable yarns contracts while the baseand the nonshrinkable yarns remains intact thereby yielding a pile madeup of high and low areas to give the appearance of an embossed or carvedproduct.

A chemical embossing method is disclosed in U.S. Pat. No. 2,020,698.According to this patent, fabric having a pile of organic ester ofcellulose yarn is locally treated with an alkali or alkaline saltsaponifying agent in order to obtain ornamental differential effects inthe treated areas. Furthermore, since the organic ester of cellulosepile yarns that have not been saponified are more difficult to changefrom their position, after they are once set than are the saponifiedorganic ester of cellulose yarns, it is possible to obtain adifferential lay between the saponified and unsaponified organic esterof cellulose pile yarn. Thus, the fabric, after the application of thesaponifying agent, many be washed, finished and dried with the pileerect, after which the fabric may be run through water and brushedacross the piece to lay the pile towards the selvage and it is thendried. This causes the saponified pile yarn to lie flat while theunsaponified yarn remains substantially erect. Upon subsequent steamingand brushing the fabrigin the opposite direction, any unsaponified yarnwhich may have been slightly bent from the vertical by the previousbrushing toward the selvage is caused to stand erect without disturbingthe position of the laid or crushed saponified organic ester ofcellulose pile yarn.

SUMMARY OF THE INVENTION It is the primary object of this invention toprovide a simple process for producing a nylon pile having a textured orembossed surface.

Another object is to provide such a process which is readily adaptableto standard printing equipment.

Another object is to provide a process which allows the production ofpile fabric having embossed areas in register with a printed design.

A further object is to provide an embossing process which is readilyadaptable to curved and irregular surfaces.

Various other objects and advantages of this invention will be apparentfrom the following detailed description thereof.

It has now been discovered that it is possible to produce superior nylonfabrics having embossed surfaces by contacting selected portions of thesurfaces with a chemical embossing agent for the fibers of said pilefabric causing dimensional change by linear contraction of the treatedfibers and, thereafter, effectively removing the embossing agent. Theresulting product is thus depressed at the treated areas.

The embossing composition can be transparent so that the appearance ofthe product is not altered other than in being embossed. Alternatively,the embossing agent can be part of a dye or pigment composition used inprinting the fabric so that the color appears in perfect register in theareas of embossing agent application.

The depth of the depressed areas can be controlled by varying theconcentration and/or type of embossing agent. This variation inconcentration can be effected by the amount of vehicle applied as wellas by the strength of the embossing reagent.

Furthermore, the embossed depth can be controlled to some degree by thedepth of penetration of the print paste carrying the embossing agent aswell as the steamer time and steamer temperatures to which the pilefabric is subjected in order to activate the chemical embossing agentwhich provide the desired effect.

This discovery makes possible the production of a product havingembossed surfaces which can be in complete register with a printeddesign. Additionally, the discovery makes possible the utilization ofmany types of printing apparatus for purposes of effecting embossing,thereby eliminating the need for expensive embossing equipment. Further,it allows the embossing of a surface without exerting sufficientpressure to permanently deform the pile fabric. A great number ofproducts can be produced by the process. They can be used for floor,wall and ceiling coverings, drapery, upholstery and the like, and, infact, wherever pile fabrics are utilized. They are readily adaptable todecorating any surface on which pile fabrics can be applied. Manyadditional applications will occur to those skilled in the art.

This invention will be better understood from the following detaileddescription thereof together with the accompanying self-explanatorydrawings in which:

FIGTI is enlarged top view of a section of an embossed product of thisinvention; and,

FIG. 2 is an enlarged cross-sectional view of the same product takenthrough line 2-2.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the production of the pilefabrics of this invention, the pile yarn employed is nylon. Syntheticfibers prepared from polyamides such as nylon are well known to thoseskilled in the art.

Likewise, the embossing agents which are applied to the nylon fibers inorder to produce the desired effect are also known chemical compounds.For purposes of this invention, the term embossing agent is defined asany active chemical composition which when applied to the pile fabricproduces a measurable reduction of pile height, but without significantdeterioration of the nylon fibers. In fact, it is our objective toinduce embossment and shrinkage without deteriorating the fiber. Theexact chemical and physical mechanism by which this result is achievedis not completely understood. However, it is believed that the embossingagent may owe its effectiveness largely to its capability to function asa hydrogen bond breaker. Initially, the fibers are in a stretched andcrystalline state. When the hydrogen bond is broken between the polymerchains, the fibers relax and shrink. Regardless of the mechanism, theoverall effect produced is one of dimensional change, the most desirableeffect, involving linear contraction of the fiber.

In order to be applicable for the novel process of this invention, theembossing agent should provide a reduction of the pile height through ashrinkage reaction, should not adversely affect the printing means,e.g., print screens, and should be capable of being substantiallyremoved or inactivated subsequent to the embossing action. othercharacteristics of the embossing agent which are desirable, though notessential, include compatibility with dye print pastes, capability ofbeing regulated by factors of time, temperature, and concentration,i.e., susceptibility to activation by a conventional steaming operationand exhibiting no residual embossing activity. Needless to say, minoradjustments in the nature of the components and process conditions,and/or the embossing apparatus can be employed to overcome the absenceof certain of these desired characteristics.

The embossing agent for the nylon fibers is applied to one surface ofthe pile fabric in any desired design, whether it be random orpredetermined. One of the easiest methods of applying the agent is byutilizing conventional printing technique such as silk screen or blockprinting. The embossing agent can be applied as a concentrate, as partof a transparent vehicle, or as part of a dye composition utilized forpile fabric printing. The nature of the embossing agent dictates thenature of the vehicle to be utilized. Among such applicable vehicles areincluded: water, and alcohols such as methanol and isopropanol. Oftenthickeners, e.g., gums. and cellulose derivatives, are included in orderto obtain viscosity characteristics demanded in print technology and toenable the embossing agent to adhere to and operate on the syntheticfiber and to hold the printed pattern.

In those instances where it is desired to achieve a singleormulti-colored printed decoration with a distinct color for the embossedareas, the embossing agent can be incorporated into a particular dye orpigment com position. The dye or pigment will generally be in the formof a print paste ink to which the appropriate amount of agent is added.lt is to be noted that in preparing these modified dye composition, thepH levels, viscosities, and dye concentrations which are essential to anefficient dyeing operation must also be controlled. The resultant effectis an embossed design in register with the printed pattern. lf differentdepths of embossing are sought, they are achieved by use of differentconcentrations of agent in the areas calling for such different depths.

Generally, it is desirable that the embossing agent be soluble or insolution in the solvent medium from which it is applied to the selectedareas of the fabric. However, if the agent is not soluble it should bein the composition in a form at least suficiently finely divided to passthrough the print screen, that is, it should be present in a micropulverized form which indicates particle diameter of the order of 100microns or smaller. That is, it must not only pass through screen but itmust pass through freely, dispersed through the dye paste throughout theprinting operation. The purpose of this, of course, is to make sure thatthe agent becomes uniformly dispersed over the fiber in the printprocess so that the shrinking effect will be uniformly developed in thefiber.

As previously indicated, the preferred embossing agnet is one which isdormant during the successive printing operations but then is activatedby the elevated temperature of a steam chamber usually utilized to fixthe dye onto the fibers. Embossing agents which can function in thismanner on nylon and produce shrinkage of the nylon fibers comprise ametal halide such as zinc chloride in combination with an acid such asacetic acid. When this combination of chemicals is added to the dyeprint paste in the proper concentrations and proportions, nylon carpetpile can be embossed deeply wihtout significant fiber deteriorationexactly in register with a printed design by shrinking the nylon fibers.While the preferred metal halides include zinc chloride, calciumchloride, lithium chloride, and aluminum chloride, other metal halidesmay be used such as zinc bromide, zinc iodide, cupric chloride, stannouschloride, stannic chloride, ferric chloride, and chromic chloride.Likewise, while acetic acid is the preferred acid, other acids may beused such as phosphoric, formic, maleic, citric, hydrochloric, sulfuric,oxalic, malonic, propionic, hydroxyacetic, and monochloroacetic. At theindividual concentrations employed in this process, the metal halidesalone, or the acids alone, are not useful. The advantages of this typeof chemical embossing agent are that there is no need for rigid timecontrol in the process and there is minimal concern regarding excessiveuncontrollable embossing because other factors can be changed. Thus, thedegree of diminution of the pile height can be controlled by adjustingthe amount of dye paste applied, the concentration of embossing agent inthe dye paste and the temperature and time of exposure in the steamchamber. All these factors can be adjusted according to properties ofthe nylon fiber comprising the pile fabric. While the depth of embossingwill be determined by the practitioner in accordance with the type ofembossed product being prepared, reduction in pile height will generallynot exceed more than this value being indicative of excellent embossingwithout exposing the backing materials.

Embossing can be achieved, if desired, by subjecting the treated fibersto heat Thus, the treated surfaces may be subjected to the radiationfrom a bank of infrared lamps, particularly where the embossing agent isriot part of a dye print paste. Additionally, even where the steamingoperation is'not essential to activate the embossing agent, suchsteaming may have the effect of increasing the penetration of theembossing agent and increasing the speed of its action on the fibers.

A critical step of the novel process of this invention involvesterminating the embossing action and/or of fecting substantial removalof the embossing agent from the pile fabric. lt may be necessary toachieve complete elimination of all residues of the embossing processwhich may contribute undesirable properties to the finished fabric, suchas odor, toxicity and color and texture change. Needless to say, anytermination or quenching technique resorted to will depend on theparticular embossing composition employed. The most useful technique forremoving residues of the embossing process is by thoroughly washing thefabric with water and detergents. In those instances where the embossingagent is part of a dye or pigment composition, the washing cycle whichis utilized to remove excess dye or pigment serves also to remove tracesof the agent. Where an acidic embossing agent is utilized, e.g., formicacid on nylon, it is possible to halt the embossing action more rapidlyby rinsing with an aqueous am- Zinc Chloride Acetic acid, Glacial moniaor mildly alkaline solution. This neutralization of 5 within theseconcentration ranges the individual the acid serves to insure the totalremoval thereof.

Other techniques for terminating the embossing action and/or removingthe embossing agent include evaporation and dry cleaning. Thus, if theagent is volatile, steaming of the treated pile fabric will serve toevaporate a large portion of the embossing pile content. Where rinsingtechniques are not effective, it may be necessary to resort to a drycleaning procedure to remove the embossing residues.

The invention has particular application to tufted carpets which are tohave a printed decoration applied thereon. Unusual design effects canalso be obtained when the pile fabric is printed with a multi-coloreddesign wherein one or more of the dye compositions contain theappropriate embossing agent. The process of printing such carpetsincludes the steps of passing carpets, tufted of unpigmented or coloredfibers, into a screen printing apparatus whereby a design is printed onthe surface of the carpet. Each screen applies a separate color to makeup the final design. The embossing agent can be added to one or more ofthese printing stations by addition to the dye composition, or it can beapplied by a separate station in a transparent vehicle. The fabric isthen passed into a steaming chamber to set the dyes and cause embossingand then to a washing cycle which serves to remove excess dye as well asto terminate the embossing action and/or remove the embossingcomponents.

Accordingly, in the embossing of carpet or textured pile fabric, and forall practical purposes we are discussing the embossing of carpeting, itis important that any color design on the surface of the carpet which isrelated to the embossing be in accurate register with the embossing.Since we are concerned only with chemical embossing the problem is thenone of inducing the differential fiber length between the embossedcolored areas and unembossed areas and, while it is possible to induceshrinkage of synthetic nylon fibers, it is necessary for preparation ofthe carpet that the fiber shrinkage be induced with no significantdeterioration of what is left. Thus, if the operation of embossinginvolves true shrinkage the shrunk fabric fiber should have a textureapproximating that of the original.

Suitable combinations of metal halide and acid will generally fallwithin approximately the following broad range of concentrations foreach component so as to obtain nylon carpet embossment to the desireddepth. These ranges represent parts per hundred of the total printpaste:

Metal halide Acid ponents used alone are not useful as carpet embossingagents.

As indicated previously, a procedure of trial and error is required inorder to arrive at the best proportions of zinc chloride and acetic acidneeded to achieve a desired depth of embossment without deterioration ofthe nylon carpet pile. It is, of course, important that the nylon fibersremain physically fibers and that the shrunk carpet pile retain itsoriginal physical character as well as acceptable appearance and feel.Generally, however, it will be found that the sum of the concentrationof zinc chloride and the concentration of acetic acid in the print pastewill fall within the limits of 40-65%. Whenever maximum carpetembossment is obtained (that depth just short of fiber deterioration,unacceptable hardness or the like) any reformulation which calls forincreasing either component should be accompanied by a reduction in theconcentration of the other component otherwise fiber deterioration willoccur.

The concentration range within which zinc chloride and acetic acid maybe selected do not necessarily hold true for other metal halides andacids. Suitable concentrations and proportions must be determined bytrial and error.

Depth of embossment as well as the deteriorating effect of the embossingagent upon the nylon carpet fibers is not only related to the strengthof the embossing agent, but is also related to the distribution andpenetration of the embossing agent into the nylon carpet pile.

Therefore, print paste viscosity is important in influencing the depthof embossing as well as the embossed pile character since it regulatesthe penetration of the dye print paste containing theembossing agentinto the carpet pile as well as the quantity of embossing agentdeposited. Both penetration and amount of embossing agent applied canalso be regulated by the number of squeegee roller strokes. Otherfactors effecting both shrinkage and attack of nylon fibers are steamertime and temperature. Too long a steamer time or too high a temperaturegenerally aggravate nylon fiber deterioration. Generally it appears thatthe maximum reduction in nylon carpet pile height will not exceed muchmore than about 50% without fiber deterioration reflected inunacceptable pile hardness, harshness, weakness, fusion, and the like.Lesser embossed depths are of course obtained by altering theproportions and/or concentrations of the components of the embossingagent.

In order to practially evaluate the utility of a particular chemical orcombination of chemicals as an embossing agent for nylon carpet, thechemical system is incorporated in the dye print paste and applied to asection of the nylon carpet by means of a screen printing technique soas to simulate plant production procedure as closely as possible. Thetreated carpet is steamed usually for 15 minutes at 215 to 220 F 102C to104 C) thoroughly rinsed with water and dried at about F. Then theembossed area. is rubbed briskly with the finger tips or for example awooden knife handle to loosen and separate tufts. 1n the plant this isaccomplished by brushing. The depth of embossment is then measured andobservations made regarding the character of the embossed nylon, e.g.,harshness, softness, strength, firmness, brittleness, intactness,definition, color. Measurement of the pile height at the embossed andunembossed area is made by means of a thin, steel ruler marked off in1/64 inch (0.4 millimeter) intervals. Any method of measurement isuseful so long as it is standardized from operation to operation and isreproducible to about 1X64 inch.

However, for the preliminary determination of whether or not a chemicalcomposition is capable of shrinking nylon fibers and for thusdetermining its potential suitability as a chemical embossing agent fornylon carpet, we have devised a simpler, less time consuming beaker testprocedure. Using this test, the per cent shrinkage and the per centweight loss experienced by a 50 centimeter loop of nylon carpet filamentor carpet yarn is determined by immersing the yarn loop in an aqueoussolution or dispersion of the test chemical for minutes at 215F 102C).This test affords a simple way of determining if a selected chemicalwill cause a shrinkage of the nylon fibers and provides a means ofpredicting whether or not a chemical will function as an embossing agentfor nylon carpet. Also, the test provides a method for determining sucheffects as chemical concentration, temperature, time, print pasteadditives, solvents other than water, nylon type and construction andthe like. Details of the test procedure are outlined as follows in Table1.

TABLE 1 BEAKER TEST PROCEDURE 1. Prepare a solution or dispersion of thechemicals to be tested in water.* If heated, cool to room temperature.Weigh 30 grams into a 32 X 200 mm test tube.

Dye print paste may be used if desired. Othcr solvents may be used,especially when other solvent based printing systems are employed.

2. Place test tube in preheated Silicone bath and heat contents of testtube to the desired temperature (usually 215F 102C).

3. Cut approximately 1 meter length of nylon yarn or filament which hasbeen held at 73F and 50% relative humidity for 24 hours, and tie in asingle loop.

4. Hang the loop under 50 gram load for 30 seconds and measure thelength of the loop to 0.1 cm.

5. Weigh loop to nearest 1/10 mg.

6. Immerse nylon loop in hot chemical solution, agitate gently andobserve any change in character of the nylon fibers. Generally hold for15 minutes or less.

7. Remove the nylon loop and wash thoroughly in copious amounts ofwater. Blot and dry to constant weight at 73F and 50% relative humidity.

8. Measure length of nylon loop as in 4.*'*

"* lf loop breaks or is already fragmented or disintegrated, or ifinsignificant shrinkage is obtained, repeat at lower or higher chemicalcon- Centratton.

9. Determine weight of nylon loop as in 5.

l0. Calculate shrinkage and weight loss.

With the information thus obtained concerning the extent of shrinkage ofthe nylon fibers as well as any deterioration of the nylon fibers, itthen becomes possible to determine whether or not the chemicalcomposition has any potential as an embossing agent, and eventuallyproceed to the formulation of a printing paste which includes theshrinking material. Experience has shown, however, that while such testresults prove that the chemical agent will shrink riylon fiber and thushas an embossing capability for nylon carpet, these results tell us onlyapproximately what concentration of the chemical agent is required toemboss nylon carpet. Nor do we know the exact extent of fiberdeterioration that will be experienced on the nylon carpet. Generally,the following relationship seems to exist between beaker test resultsand screen printing test results on nylon carpet. Beaker test shrinkageresults must reach at least about 50% shrinkage in 15 minutes at 215F(l02C) in order for an embossing agent to produce even trace to very weakcarpet embossment But Beyond about 50% shrinkage via the beaker test,the nylon filament begins to deteriorate rapidly (test loop weakeningand fragmentation). On the other hand, it appears that deeply embossedcarpet can only be anticipated if the chemical shrinking agent causesfiber destruction in the beaker within about 60 seconds. The maximumdepth of embossment obtainable without causing unacceptable nylon carpetfiber deterioration is usually about 50%.

Apparently, the difference between beaker test shrinkage resultsobtained on a loop of nylon filament of yarn, and screen printing testresults obtained on nylon carpet, occurs because the chemical isutilized much less effectively on the carpet pile than in the beakertest. Screen printing does not supply sufficient print paste (containingembossing agent) to the nylon carpet pile to provide a completelyuniform coating of the nylon fibers. Furthermore, the depth ofconcentration into the carpet pile is often of the order of only about50%. Also, during steaming, the concentration of the embossing agent maybe reduced and chemical which may be consumed is not replaced. However,in the beaker test, the nylon loop is surrounded constantly anduniformly by a surplus of hot chemical solution of practically the sameconcentration throughout the duration of the test thus allowing thechemical to function more effectively.

The following examples will further illustrate the embodiment of thisinvention. In these examples, all parts given are by weight unlessotherwise noted.

EXAMPLE I The shrinkage and weight loss experienced by a test loop ofDuPont type 846 bulk continuous filament nylon 6/6 (1,300 denier, 68filaments, o twist, semidull, regular acid dyeable) was determined bymeans of the beaker test procedure described in Table 1 using thefollowing aqueous recipes containing zinc chloride in combination withacetic acid at the concentrations of total batch) indicated. The testtemperature and maximum duration of test was 215F and 15 minutesrespectively.

Test results tabulated in Table 11 show that the chemical compositioncomprising zinc chloride and acetic acid can produce effects on nylonfibers ranging from strong shrinkage with fiber deterioration (usuallyabout 50%) to immediate fiber disintegration depending upon theproportions and concentrations of chemicals used. Thus, these dataindicate that the zinc chloride/acetic acid system has a strongpotential as an embossing agent for nylon carpet since it is capable ofcausing fiber disintegration via the beaker test procedure within about60 seconds. Generally zinc chloride/acetic acid combination whichinduces 50% shrinkage of nylon fiber in the beaker test will be found toproduce very little carpet embossment.

At the maximum individual concentrations employed, neither zinc chloride(30%) nor acetic acid (30%) used alone, yield significant fibershrinkage. In fact, the nylon fiber shrinkage induced is not muchgreater than obtained with water alone.

of test was 215F 102C) and 15 minutes respectively.

Test results (Table 111) show that metal halides in acetic acid solutionserve very effectively as shrinking agents for nylon fibers. Dependingupon the particular metal halide and the ratio and concentration ofmetal halide and acetic acid, effects are produced ranging from strongfiber shrinkage to fiber destruction within about 60 seconds.Combinations which produce this Avg. 13 runs in water alone at 212FEXAMPLE u The shrinkage and weight loss experienced by a test loop ofDuPont type 846 bulk continuous filament nylon 6/6 (1,300 denier, 68filaments, o twist, semidull, regular acid dyeable) was determined bymeans of the beaker test procedure described in Table I using theaqueous recipes shown in Table 111 containing a combination of aceticacid and a metal halide other than zinc chloride. The test temperatureand maximum duration latter effect can be anticipated to produce deepcarpet embossment.

It will be observed that at the individual concentrations employed,neither the metal halides alone, nor the acetic acid alone, causesufficient shrinkage of the nylon filament to produce carpet embossment.Usually at least 50% shrinkage of the nylon filament is required beforeperceptible carpet embossment can be expected.

TABLE 111 Nylon Filament Acetic Shrink Wt. Run Metal Halide Acid ageLoss Loop No. type Character Water (tap) 7.03 0.68 Good 359 Acetic Acid25 12.3 1.32 Good 659 Acetic Acid 0 45 27.0 392 Good 834 Cesium Chloride25 25 13.3 123 Good 717 Sodium Chloride 25 25 lnsoluble 761 LithiumChloride 30 0 7.2 +1.3 Good 711 Lithium Chloride 25 25 60.2 2.67Excellent 728 Lithium Chloride 25 30 Solid mass 15 secs. 796 LithiumChloride 15 45 Disintegrate 20 secs. 784 Potassium lodide 50 0 6.9 +3.01Good 712 Potassium lodide 25 25 18.6 1.01 Yellow 749 Potassium lodide 3030 39.7 3.28 Yellow 762 Zinc Chloride 30 0 18.1 +1.76 Good 760 ZincChloride 20 20 33.1 3.41 Good 690 Zinc Chloride 25 20 71.4 6.31 V. Weak797 Zinc Chloride 15 45 Disintegrate secs. 836 Barium Chloride .2H O 2525 19.1 1.34 Good 765 Zinc Bromide 30 0 17.2 0.13 Good 744 Zinc Bromide20 22.5 40.6 4.28 Good 742 Zinc Bromide 25 25 Disintegrate secs. 835Manganese Chloride .4H O 25 25 22.3 1.97 Good 764 Ferric Chloride .6H,O30 0 15.9 +11.7 Orange 754 Ferric Chloride ,6H,O 20 45.8 1.49 Yellow 743Ferric Chloride til-1,0 25 Solid mass secs. 799 Ferric Chloride .6H,O 15Solid mass 15 secs.

766 Zinc lodide 30 0 34.1 +6.53 Brown 758 Zinc lodide 20 20 42.2 0Orange 757 Zinc lodide 25 20 Solid mass 15 secs. 748 Zinc Fluoride 25 25lnsoluble 721 Lead Chloride 25 25 lnsoluble 785 Nickel Chloride .6H,O 08.2 +0.8 Good TABLE 111 Continued Nylon Filament Acetic Shrink Wt. RunMetal Halide Acid age Loss Loop No. type 7: ('71) ("/1 ('16) Character720 Nickel Chloride .6H,O 25 25 22.4 2.2 4 Crood 753 Nickel Chloride .6H30 30 34.5 2.95 Good 786 Magnesium Chloride .6H,O 50 0 7.6 +1.46 Good715 Magnesium Chloride .6H,O 25 25 19.9 1.80 Good 750 Magnesium Chloride.6H,O 30 30 35.2 2.96 Good 767 Cupric Chloride .2H,O 0 8.0 +2.65 Green716 Cupric Chloride .2H O 25 25 30.0 2.85 Yellow 756 Cupric Chloride.2H,O 30 30 Fragmented 15 mins. 783 Calcium Chloride .2H,O 30 0 11.4+1.23 Good 416 Calcium Chloride .2H O 25 25 48.1 4.28 Good 729 CalciumChloride .2H,O 30 30 Solid mass 30 secs. 802 Calcium Chloride .2H O 1545 Disintegrate 5 secs. 769 Stannous Chloride .2H,O 30 0 11.3 +20.3 Good709 Stannous Chloride .2H,O 25 25 57.0 +34.8 V. Weak 727 StannousChloride .2H O 25 30 Solid mass 30 secs. 798 Stannous Chloride .2H,O 45Disintegrate 5 secs. 787 Cobaltous Chloride .6H O 50 0 91.3 +2.63 Blue718 Cobaltous Chloride .6H,O 25 25 19.4 1.98 Good 751 Cobaltous Chloride.6H,O 30 30 36.8 3.76 Good 770 Chromic Chloride .6H,O 30 0 9.6 +1.53Green 731 Chromic Chloride .6H,O 25 45.8 7.2 V. Weak 791 ChromicChloride .6H,O Disintegrate 10 secs. 803 Chromic Chloride .6H,O 15 45Disintegrate 5 secs. 771 Aluminum Chloride .6H,O 30 0 8.5 +1.0 Good 406Aluminum Chloride .6H,O 25 25 55.5 8.9 Good 714 Aluminum Chloride .6H ,025 30 Disintegrate 20 secs. 801 Aluminum Chloride .6H O 15 45Disintegrate 5 secs. 763 Stannic Chloride .SH O 30 0 25.8 +34.0 Good 759Stannic Chloride .5H,O 20 20 46.8 +67.7 Weak 710 Stannic Chloride .5H,O25 25 Solid mass 20 secs. 800 Stannic Chloride .5H,O 15 45 Disintegrate5 sec.

' Avg. 3 runs Nos. 778, 788, 804 Good No appreciable deterioration ofnylon filament. No discoloration. Insoluble at room temperature and 215FEXAMPLE 111 The shrinkage and weight loss experienced by a test loop ofDuPont type 846 bulk continuous filament nylon 6/6 (1,300 denier, 68filaments, o twist, semidull, regular acid dyeable) was determined bymeans of the beaker test procedure described in Table 1 using zincchloride and acids other than acetic acid. The test temperature and themaximum duration of testing was 215F and 15 minutes respectively.

Recipes and test results are shown in Table IV. These data show thatacids other than acetic acid can be used successfully with zinc chlorideto provide a strong shrinking agent for nylon fibers. These acidsinclude phosphoric, formic, maleic, citric, hydrochloric, sulfuric,oxalic, malonic, hydroxyacetic, propionic and monochloroacetic.Depending upon the acid employed, and the ratio and concentrations ofacid and zinc chloride used, the extent of shrinkage can range from veryweak after 15 minutes at 215F to total destruction of the nylon filamentwithin about 60 seconds. Combinations which produce this latter effectcan be anticipated to produce strong embossment of nylon carpet.However, it may occur that a shrinking agent which exhibits adisintegrating time of a few seconds in the beaker will prove to be toodestructive for carpet embossment. In this case, the ratio andconcentration of chemicals must be changed by trial and error so as toproduce the desired embossment.

At the individual concentrations used, neither the zinc chloride alone,nor the acids alone, provide sufficient shrinkage of the nylon filamentto produce carpet embossment.

It would be expected that other metal halides besides zinc chloridewould also perform satisfactorily with other acids besides acetic acid.For example, 25 '70 calcium chloride dihydrate combined with 25monochloroacetic acid in 50 water (Run no. 807) caused nylon filament todisintegrate in 20 seconds at 2l5F. A weaker concentration comprising20/20, calcium chloride .2H O, monochloroacetic acid produced a filamentshrinkage of 64% (Run No. 882).

TABLE IV Nylon Filament Zinc Shrink Wt.

Run Acid Chloride age Loss Loop No. Type (7:) (7r) (7e) (72) CharacterWater (tap) 7.03 0.68 Good 762 Zinc Chloride 0 30 18.1 +1.76 Good 859Acetic Acid 25 0 12.3 1.32 Good 760 Acetic Acidv 20 20 33.1 3.41 Good708 Acetic Acid 25 25 Disintegrate 5 secs. I51 Phosphoric Acid 25 0 16.5+2.36 Good 874 Phosphoric Acid 20 20 Solid mass 30 secs. 860 PhosphoricAcid 25 25 Solid mass 20 secs.

TABLE IV Continued Nylon Filament Zinc Shrink Wt. Run Acid Chloride ageLoss Loop yp Character 147 Formic Acid 25 22.1 2.06 Good 875 Formic Acid20 20 53.0 4.67 Weak Spot 861 Formic Acid 25 25 Solid mass secs. 688Maleic Acid 25 0 13.8 0.7] Good 867 Maleic Acid 20 47.4 5.06 Good 862Maleic Acid 25 Solid mass 10 sees. 92 Citric Acid 50 0 23.8 +4.03 Good877 Citric Acid 20 20 20.4 1.33 Good 865 Citric Acid 25 25 Solid mass 2mins. 382 Hydrochloric Acid 7.4 0 15.1 3.25 Good 878 Hydrochloric Acid10 20 Disintegrate 6 secs. 686 Sulfuric Acid 10 0 8.2 0.19 Good 879Sulfuric Acid 12 20 Disintcgrate 10 secs. 683 Oxalic Acid .2H,O 35 019.6 1.80 Good 881 Oxalic Acid .2H,O 20 20 Disintegrate 10 secs. 244Malonic Acid 35 0 18.0 1.61 Good 880 Malonic Acid 20 20 29.1 3.28 Good870 Malonic Acid 25 25 Solid mass 10 secs. 684 Hydroxyacetic Acid 25 08.4 0.58 Good 871 Hydroxyacetic Acid 25 25 46.0 3.16 Weak Spot 687Propionic Acid 25 0 19.2 2.28 Good 896 Propionic Acid 25 25 Disintegrate10 secs. 897 Monochloroacetic Acid 25 0 22.7 1.72 Good 554Monochloroacetic Acid 21 21 Solid mass 20 secs. 568 MonochloroacetciAcid 24 20 Solid mass secs. 558 Monochloroacctic Acid 21 18 59.1 4.18Good Good No apprcciable deterioration of nylon filament. Nodiscoloration. Avg. 3 runs Nos. 778. 778. 804 Insoluble material at 215FEXAMPLE IV This example illustrates the preparation of an embossed pilefabric typical of the products of this inventron.

A 4 inch by 7 12 inch rectangular area of nylon carpet was treated bymeans of a screen printing technique with a dye print paste containing25% zinc chloride and 25% glacial acetic acid by weight as the embossingagent.

Carpet construction was as follows:

Type 100% Nylon 6/6, spun yarn, non heat set Face Weight 28 oz./yd. sq.(950 grams/sq. meter) Machine Gauge 5/32 inch (3.96 millimeters) MachineStitch Rate 9.6 stitches/inch (3.8 stitches/- centimeter) Pile Height17/32 inch, singles (1.35 centimeters) The dye print paste recipe was asfollows:

SAMPLE NO. 41 9SP-l 2 Sulfuric acid ester. lcvclling agent andpenetrating agent.

3 Alcohol ether, antifoaming agent 4 Locust hcan gum thickener providinga Brookfield viscosity of 600 cps. at 78F (No. 3 spindle 2% rpm).

There was no evidence of embossing while the nylon carpet was held atroom temperature for several minutes. Upon subjecting the carpet tosteaming for 15 minutes at about 218F, significant embossing due tofiber shrinkage was observed. Thereafter, the embossed carpet wasthoroughly rinsed with water and dried. The rinsing removed residualchemicals.

The resulting carpet exhibited excellent embossing with a 41% reductionin pile height in the treated area in perfect register with the printedrectangle. Despite this degree of shrinkage, the nylon tufts afterrubbing retained their individuality and were soft and strong. There wasno evidence of deterioration of fiber physical properties.

EXAMPLE V A series of adjacent parallel rectangular areas of nyloncarpet measuring 6 inches wide by 2 inches, 1 inch, 15 inch, A inch, and/s inch respectively were treated simultaneously by means of a screenprinting technique with a dye print paste containing 25% zinc chlorideand 25% glacial acetic acid by weight as the embossing agent.

Carpet construction was as follows and differed from the carpetconstruction utilized in Example IV with respect to heat setting, faceweight, machine stitch-rate, and twist.

Type Nylon 6/6. spun yarn, heat set Face Weight 40 oz./sq. yd. (1,356grams/sq. meter) Machine Gauge 5/32 inch (3.96 millimeters) MachineStitch Rate 7 stitches/inch (2.76 stitches/- centimeter) Pile Height17/32 inch, doable twist (1.35 centimeters) The dye print paste recipewas as follows. In this instance, the thickener employed was an Xanthangum instead of the locust bean gum used in Example 1V.

SAMPLE NO. 452SP-2 Materials Grains 1. Water 32.7 2. Cibaphasol AS 0.53. Antifoam 73 0.8 4. Kclzan (171) (0.2% Dowicide A) 16.0 5. AceticAcid. Glacial 25.0 6. Zinc Chloride 25.0 7. Dyc 0.05

' 4 Xanthan gum thickener plus preservative in water to provide aBrookfield viscosity of I080 cps. at 78F (No. 3 spindle, 2% rpm).

Again, there was little evidence of embossing while the nylon carpet washeld at room temperature. Upon subjecting the carpet to steaming atabout 2l7F for a period of minutes, significant embossing resulted dueto shrinkage of the nylon carpet pile. Thereafter, the carpet was rinsedand dried.

The resulting carpet exhibited a 35% reduction in pile height at the 2inch by 6 inch area exactly in register with the printed area. A similarreduction in pile height was noted for the 1 inch by 6 inch area.However, the narrower width prints produced only about a 26% reductionin pile height (A inch wide) and a 18% reduction in pile height (/8 inchwide). These latter two reductions in pile height are a reflection ofthe reduction in the print paste penetration at very narow printed areaswhen no changes are made in print paste viscosity to compensate fornarrow embossments. The embossed nylon pile was rubbed briskly. Thetufts retained their individuality and were soft and strong. There wasno evidence of deterioration of fiber physical properties.

EXAMPLE V] SAMPLE NO. 903SP-l Materials Grams 1. Water 22.7 2.Cibaphasol AS 0.5 3. Antifoam 73 0.8 4. Kelzan (lVzCi (0.2% Dowicidc A)16.0 5. Acetic Acid, glacial 45.0 6. Lithium Chloride I50 7. Dye 0.05

' 2 and 3 same as described in Example IV, 4 Xanthan gum thickener inwater plus the preservative Dowieide A yielding a Brunltl'ield viscosityof I040 cps. at 7XF (No. 3 spindle, 2V2 rpm).

Upon subjecting the printed carpet to steaming at 2 l 7F for 15 minutes,significant embossing developed due to shrinking of the nylon carpetpile by the embossing agent. While the carpet was held at roomtemperature for a few minutes prior to steaming, there was no evidenceof embossing. After steaming. the carpet was washed and dried.

The resulting carpet showed a 41% reduction in pile height exactly inregister with the printed area. Despite this deep embossment, the rubbednylon tufts retained there original character except for increasedfirmness and some slight hardness.

EXAMPLE Vll .2l-l O as the embossing agent. ln both instances, the

nylon carpet construction was the same as cited in Example IV.

The dye print paste recipes were as follows:

Materials* Sample No.

670SP-l 9l4SP-l l. Water (tap) 35.2 39.7 2. Cibaphasol AS 0.5 0.5 3.Antifoam 73 0.8 0.8 4. Polygum 260 (5%) 19.5 5. Kelzan l%%) (0.2%Dowicide A) l5.0 6. Monochloroacetic Acid 24.0 24.0 7. Zinc Chloride20.0 8. Calcium Chloride .2H O 20.0 9. Dyc 0.05 0.05

2.3.4, and 5 same as described in Examples IV and V,

Print paste viscosity was 40 cps. at 78F for Sample No. 670SP-l and1,000 cps. at 78F for Sample No. 9l4SP-l. (Brookfield No. 3 spindle, 2/2 rpm).

There was no sign of embossment while the printed nylon carpets remainedat room temperature for several minutes. But after steaming for 15minutes at 217F, significant embossing due to fiber shrinking wasobserved. Thereafter, the embossed carpets were thoroughly rinsed withwater and dried. The rinsing removed residual chemicals.

Both of the resulting carpets exhibited excellent embossing in perfectregister with the printed design. Pile reduction amounted to 47% forsample 67OSP- 1, while the reduction in pile height for sample 914SP-lwas 35%. After rubbing the dried, embossed areas, the resulting pile wassoft, firm, and strong for both carpets. There was no apparentdeterioration of fiber physical properties in either case.

EXAMPLE Vlll Embossed nylon carpets were prepared using the embossingprocedure and carpet construction cited in Example IV. Variouscombination of metal halide and acid were employed as follows:

45% Acetic Acid, 15% Calcium Chloride .2H O

25% Acetic Acid, 30% Aluminum Chloride .6H O

22.5% Formic Acid, 25% Zinc Chloride 20.0% Phosphoric Acid, 25% ZincChloride The dye print paste recipes used were as follows (Table V):

TABLE V Carpet Sample No.

Material" 907SP-1 910SP-l 9l3SP-l 9l1SP-l 1. Water (tap) 23.7 29.2 33.234.2 2. Cibaphasol AS 0.5 0.5 0.5 0.5 3. Antifoam 73 0.8 0.8 0.8 0.8 4.Kelzan (1%%) (0.2% Dowicide A) 15.0 14.5 15.5 16.0 5. Acetic Acid 45 O25.0 6. Formic Acid (90%) 25.0 7. Phosphoric Acid (85%) 23.5 8. CalciumChloride .2H O 15.0 9. Aluminum Chloride .6H O 30.0 10. Zinc Chloride25.0 25.0 l 1. Dye 0.05 0.05 0.05 0.05 12. Brookfield viscosity (cps)1920 960 1000 1080 Z Sulfuric acid ester. leveling and penetratingagent. 3 Alcohol ether. untifoaming agent.

4 Xunthan gum thickener plus preservative Dowicide A in water yieldingthe Brookficld viscosities indicated at 78F (No. 3 spindle 2% rpm).

room temperature before steaming. Upon subjecting the carpet to steamingfor 15 minutes at about 217F, deep embossing due to fiber shrinkage wasnoted. Thereafer, the embossed carpet was thoroughly rinsed with waterand dried.

The resulting carpet exhibited deep embossment amounting to 41% inperfect register with the treated area. After rubbing, the nylon tuftsretained their individuality and were soft and strong. There was noevidence of deterioration of fiber physical properties.

Emboss- Sample m No. Embossing System (90) 907SP 1 Acetic Acid. CalciumChloride .2H,O, 45/15 29 9 l()SP-I Acetic Acid. Aluminum Chloride.6H-,O. 2. /30 29 9 USP-1 Formic Acid, Zinc Chloride, 22.5/25 41 91lSP-l Phosphoric Acid, Zinc Chloride. 20/25 38 After rubbing, the shrunktufts were defined, strong and soft for the first three of the foregoingembossed carpets; while the tufts were firmer and somewhat harsh for thecarpet embossed with the phosphoric acid/zinc chloride, 20/25 system.

EXAMPLE [X SAMPLE NO. 906SP-l Material grams 1. Water (tap) 42.7 2.Cibaphasol AS 0.5 3. Antifoam 73 0.8 4. Kclzan (lk'7r) (0.2% Dowicidc A)16.0 5. Maleic Acid 25.0 6. Zinc Chloride 25.0 7. Dyc 0.05

' 2. 3. and 4 same as described in Example Vlll except Brookficldviscosity was not obtained.

Once again there was no indication of embossing while the nylon carpetwas held for several minutes at EXAMPLE X Additional embossed nyloncarpets were prepared by means of the embossing procedure and carpetconstructions described in Examples 1V and V utilizing variousconcentrations and proportions of zinc chloride and acetic acidcontianed in the dye print paste as shown in Table VI. Print pasteviscosities were varied from 680 cps. to 4,560 cps. Two thickeners wereused, a locust bean gum andan Xanthan gum.

The resulting carpet samples exhibited embossed depths ranging from 25%to 41% depending upon the proportins and concentrations of zinc chlorideand acetic acid, the carpet construction and the dye print pasteviscosity. Pile character ranged from soft to hard and harsh. Certainprint paste recipes containing the zinc chloride and acetic acid will beseen to have a destructive effect on the nylon fibers. This may beattributed generally to too strong an embossing system and- /or too higha dye print paste viscosity. in the former case, the condition can becorrected by altering the concentrations and/or proportions of theacetic acid and zinc chloride. In that latter case, a reduction inviscosity will be beneficial. 1t appearsthat too high a print pasteviscosity caused excessive bulidup of embossing agent to a shallow depthof the carpet pile resulting in a localized concentration of embossingagent that is too strong. Conversely, the print paste viscosity must notbe too thin or excessive lateral bleed will occur resulting in loss ofdesign fidelity and embossed effect.

1n the production of the pile fabrics of this invention, the pile yarnemployed is prepared from fiber-forming synthetic linear polyamides.Examples of these fiberforming synthetic linear polyamides are thoseobtainable from polymerizable monoaminomonocarboxylic acids and theiramide-forming derivatives including caprolactam and those obtainablefrom the reaction of suitable diamines with suitable dibasic carboxylicacids or their amide-forming derivatives. Such synthetic linearpolyamides are referred to as nylon.

Nylon or polyamide polymers, filaments and fibers are well known tothose skilled in the art and extensive discussion is, therefore,unnecessary. Thus the term polyamide or nylon is known to include anylong chain synthetic polymeric amide which has recurring amide groups asan integral part of the main polymer chain and which is capable of beingformed into a filament in which the structural elements are oriented inthe direction of the axis of the chain.

Polyamide resins coming within this definition and contemplated in thepractice of the present invention are formed generally by reaction of adicarboxylic acid with a diamine or by the self-condensation of anaminocarboxylic acid. Illustrative of these polyamide resins arenylon-6,6, prepared by the condensation of hexamethylenediamine andadipic acid; nylon-6,10, prepared from hexamethylenediamine and sebacicacid, both of the foregoing having, as prepared, molecular weightsexceeding 10,000; nylon-6 produced by thermal polymerization ofepsilon-aminocaproic acid or caprolactam; nylon-l1, theself-condensation produce of ll-aminoundecanoic acid; as well as avariety of polymers prepared from polymerized, unsaturated fatty acidsand polyamino compounds.

The practice of the present invention has, however, particularapplication to solid melt-extrudable and orientable fiber-formingpolyamides and more particularly to fibers and filaments preparedtherefrom which have a denier and tenacity appropriate, and well knownto those skilled in the art, for use in carpet, rugs, tapestry and thelike. Illustrative of these polyamides are those having a filamentdenier of 2-30 or higher or nylon yarns in the denier range of 15-]5,000 or higher. The tenacities of nylon yarn for use herein are withinthe range of 3-10 grams per denier. The elongation of commercial fiberscan range between 16 to 65%. The undrawn filament is capable of beingstretched as much as 5 times. It is understood additionally thatencompassed within the polyamides that can be employed in the practiceof this inventionare high molecular weight synthetic linear polyamides,in addition to those described hereinabove, that have been modified, forexample, to enhance their usefulness for particular applications.

An extended discussion of polyamides of sufficiently high molecularweight to be capable of being melt spun into filaments and comiingwithin the contemplation of this invention appears in DE. Floyd,Polyamide Resins, Reinhold Plastics Application Series, ReinholdPublishing Corporation, N.Y., N.Y. (2nd Printing 1961), and H.R.Mauersbergcr. Matthews Textile Chemical Properties, John Wiley and Sons,lnc., New York N.Y., pp. 933-971, 1034., (6th ed. 1954), Mary E. Carter,Essential Fiber Chemistry, Marcel Dekker, Inc, New York 22 1971, pp.91-109, and HF. Mark, S.M. Atlas, E. Cernia (Edited by), Man-MadeFibers, Science and Technology Volume 2, lnterscience Publishers 1968,pp. 181-295, and Tech.-Talk from Monsanto Textiles Division, BulletinTT-35 August 1969.

Summarizing, it is thus seen that this invention provides a novel andeffective method for embossing nylon pile fabrics.

Variations may be made in procedures, proportions, and materials withoutdeparting from the scope of the invention as defined in the followingclaims.

What is claimed is:

l. A process for producing an embossed effect on nylon pile fabrichaving a surface of nylon fibers which comprises,

applying to defined areas of the pile surface of said fabric a chamicalembossing agent for said fibers, said agent being blended into a liquidbase vehicle and being a metal halide and an acid,

allowing said embossing agent in its vehicle to remain in contact withsaid fibers for a period of time and at a temperature sufficient toreduce the height of said pile, without deterioration of said fibersand, thereafter, effectively removing the embossed agent from thefabric,

said reduction in height of the fibers being in the area contacted bysaid embossing agent only and being a reduction sufficieint to display asignificant embossed effect in the overall fabric.

2. The process of claim 1 wherein said embossing agent is a metal halideselected from the group zinc, calcium, lithium, aluminum, copper(cupric), tin (stannous), tin (stannic), ferric, chromic,

and an acid selected from the group acetic, phosphoric, formic, maleic,citric, hydrochloric, sulfuric, oxalic, malonic, propionic,hydroxyacetic, monochloracetic in concentrations of 5 per cent to 50 percent metal halide and per cent to 5 per cent acid, by weight, of totalembossing composition.

3. The process of claim 2 wherein said embossing agent is incorporatedin a transparent vehicle therefor.

4. The process of claim 2 wherein said embossed effect is made inregister with a'printed color design on said fabric and said vehicle isa dye printing paste carrying said embossing agent.

5. The process of claim 2 wherein said embossing action occurs withinapproximately 15 minutes at a temperature above 50C.

6. The process in accordance with claim 5 wherein said embossing actionoccurs in a steam environment.

7. The process of claim 6 wherein said embossing composition is presentin a concentration of about 40 to percent in the vehicle therefor.

8. The process of claim 1 wherein said embossing agent is zinc chlorideand acetic acid containing 15-30 percent zinc chloride and 45-25 percentacetic acid.

9. The process of claim 8 wherein said embossing agent is zinc chlorideand acetic acid, in equal percentage at about 25-25 percent.

10. The process of claim 7 wherein said embossing agent is calciumchloride and acetic acid.

11. The process of claim 7 wherein said embossing agent is aluminumchloride and acetic acid.

12. The process of claim 7 wherein said embossing agent is zinc chlorideacid.

13. The process of claim 7 wherein said embossing agent is zincechloride and monochloroacetic acid.

14. The process of claim 7 wherein said embossing agent is zinc chlorideand hydrochloric acid.

15. The processof claim 7 wherein said embossing agent is zinc chlorideand maleic acid.

16. The process of claim 7 wherein said embossing agent is lithiumchloride and acetic acid.

17. The process of claim 7 wherein said embossing agent is cupricchloride and aceetic acid.

18. The process of claim 7 wherein said embossing agent is stannouschloride and acetic acid.

19. The process of claim 7 wherein said embossing agent is stannicchloride and acetic acid.

20. The process of claim 7 wherein said embossing agent is ferricchloride and acetic acid.

21. The process of claim 7 wherein said embossing agent is chromicchloride and acetic acid.

22. The process of claim 7 wherein said embossing agent is zinc bromideand acetic acid.

23. The process of claim 7 wherein said embossing agent is zinc iodideand acetic acid.

24. The process of claim 7 wherein said embossing agent is zinc chlorideand formic acid.

25. The process of claim 7 wherein said embossing agent is zinc chlorideand phosphoric acid.

26. The process of claim 7 wherein said embossing agent is zinc chlorideand propionic acid.

27. The process of claim 7 wherein said embossing agent is zinc chlorideand oxalic acid.

28. The process of claim 7 wherein said embossing agent is zinc chlorideand malonic acid.

29. The process of claim 7 wherein said embossing agent is zinc chlorideand sulfuric acid.

30. The process of claim 7'wherein said embossing agent is calciumchloride and monochloroacetic acid.

1. A PROCESS FOR PRODUCING AN EMBOSSED EFFECT ON NYLON PILE FABRICHAVING A SURFACE OF NYLON FIBERS WHICH COMPRISES, APPLYING TO DEFINEDAREAS OF THE PILE SURFACE OF SAID FABRIC A CHEMICAL EMBOSSING AGENT FORSAID FIBERS, SAID AGENT BEING BLENDED INTO A LIQUID BASE VEHICLE ANDBEING A METAL HALIDE AND AN ACID, ALLOWING SAID EMBOSSING AGENT IN ITSVEHICLE TO REMAIN IN CONTACT WITH SAID FIBERS FOR A PERIOD OF TIME ANDAT A TEMPERATUE SUFFICIENT TO REDUCE THE HEIGHT OF SAID PILE, WITHOUTDETERIORATION OF SAD FIBERS AND, THEREAFTER, EFFECTIVELY REMOVING THEEMBOSSED AGENT FROM THE FABRIC, SAID REDUCTION IN HEIGHT OF THE FIBERSBEING IN THE AREA CONTACTED BY SAID EMBOSSING AGENT ONLY AND BEING AREDUCTION SUFFICIENT TO DISPLAY A SIGNIFICANT EMBOSSED EFFECT IN THEOVERALL FABRIC.
 2. The process of claim 1 wherein said embossing agentis a metal halide selected from the group zince, calcium, lithium,aluminum, copper (cupric), tin (stannous), tin (stannic), ferric,chromic, and an acid selected from the group acetic, phosphoric, formic,maleic, citric, hydrochloric, sulfuric, oxalic, malonic, propionic,hydroxyacetic, monochloracetic in concentrations of 5 per cent to 50 percent metal halide and 60 per cent to 5 per cent acid, by weight, oftotal embossing composition.
 3. The process of claim 2 wherein saidembossiing agent is incorporated in a transparent vehicle therefor. 4.The process of claim 2 wherein said embossed effect is made in registerwith a printed color design on said fabric and said vehicle is a dyeprinting paste carrying said embossing agent.
 5. The process of claim 2wherein said embossing action occurs within approximately 15 minutes ata temperature above 50*C.
 6. The process in accordance with claim 5wherein said embossing action occurs in a steam environment.
 7. Theprocess of claim 6 wherein said embossing composition is present in aconcentration of about 40 to 65 percent in the vehicle therefor.
 8. Theprocess of claim 1 wherein said embossing agent is zinc chloride andacetic acid containing 15-30 percent zinc chloride and 45-25 percentacetic acid.
 9. The process of claim 8 wherein said embossing agent iszinc chloride and acetic acid, in equal percentage at about 25-25percent.
 10. The process of claim 7 wherein said embossing agent iscalcium chloride and acetic acid.
 11. The process of claim 7 whereinsaid embossing agent is aluminum chloride and acetic acid.
 12. Theprocess of claim 7 wherein said embossing agent is zinc chloride acid.13. The process of claim 7 wherein said embossing agent is zincechloride and monochloroacetic acid.
 14. The process of claim 7 whereinsaid embossing agent is zinc chloride and hydrochloric acid.
 15. ThepRocess of claim 7 wherein said embossing agent is zinc chloride andmaleic acid.
 16. The process of claim 7 wherein said embossing agent islithium chloride and acetic acid.
 17. The process of claim 7 whereinsaid embossing agent is cupric chloride and aceetic acid.
 18. Theprocess of claim 7 wherein said embossing agent is stannous chloride andacetic acid.
 19. The process of claim 7 wherein said embossing agent isstannic chloride and acetic acid.
 20. The process of claim 7 whereinsaid embossing agent is ferric chloride and acetic acid.
 21. The processof claim 7 wherein said embossing agent is chromic chloride and aceticacid.
 22. The process of claim 7 wherein said embossing agent is zincbromide and acetic acid.
 23. The process of claim 7 wherein saidembossing agent is zinc iodide and acetic acid.
 24. The process of claim7 wherein said embossing agent is zinc chloride and formic acid.
 25. Theprocess of claim 7 wherein said embossing agent is zinc chloride andphosphoric acid.
 26. The process of claim 7 wherein said embossing agentis zinc chloride and propionic acid.
 27. The process of claim 7 whereinsaid embossing agent is zinc chloride and oxalic acid.
 28. The processof claim 7 wherein said embossing agent is zinc chloride and malonicacid.
 29. The process of claim 7 wherein said embossing agent is zincchloride and sulfuric acid.
 30. The process of claim 7 wherein saidembossing agent is calcium chloride and monochloroacetic acid.